Fabricated Steel Access Solutions 2015

Fabricated Steel Access Solutions

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EJ manufacture an extensive range of access solutions in a variety of materials - galvanised steel, stainless steel, aluminium, ductile iron and composite in our world class production facilities, certified to the ISO 9001, ISO 14001 and OHSAS 18001 management systems.

Suitable for Water, Sewer, Industrial, Telecommunications, Power and Rail applications, our access covers are available in hinged or drop- in formats, with lift assistance in accordance with manual handling regulations. Fall protection safety grids and a range of locking variants are also available.

Our Birr, Ireland facility accredited to ISO 9001, ISO 14001 and OHSAS 18001 management systems.

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Table of Contents

Drawings,photographs and weights are given as an indication only.Our policy is one of continuous product improvement, we reserve the right to modify product specifications without prior notice.

Product Description Page

Fabricated Steel Above Ground covers and frames 5

Flush Fit covers and frames 7

Drop in covers and frames 9

Recessed covers 10

Hinged recessed covers 11

Safety and Security accessories 13

2

Guide to Product Selection 3

Installation Instructions 15

Corrosion Protection 17

Network Security 17

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Guide to selecting your choice of Fabricated Steel solution From the site survey stage through to the design, installation and maintenance of your product, EJ are committed to working with you, offering custom built access solutions that meet the highest standards in the world. Select your choice of access cover from the options listed below by using the abbreviations (in bold) and following the column sequence, for example Cover type, Loading, Finish, Size / Chamber opening etc.

A flush fit cover,125kN loading, solid top with a clear opening of 1500 x 700mm, hinged, torsion spring, odour sealed and lockable would contain the following abbreviations:

FF 2 S 150 070 A H J V1

Access Covers - Solid Top

A drop-in recessed cover,15kN loading, with a clear opening of 600 x 600mm, 80 mm depth of recess would contain the following abbreviations:

TR 1 R 060 060 R80

100 µm = 100 Micron Galvanisation

140 µm= 140 Micron Galvanisation

IM = Insect Mesh

AB = Alarm Bracket

AI = Alarm Installed

MS = Motion Sensor Installed

DS = Double Skin - secondary protection

VS = Vibration Sensor (only available on Double Skin units)

PT = Painted

AS = Anti-skid coating

EC = Epoxy Coating

ME = Moat Draining Externally

MI = Moat Draining Internally

Access Covers - Recessed type

Additional Security for Key Assets

Accredited by the Loss Preventation Certification Board (LPCB)

LPCB Security Rating 3 SR3

LPCB Security Rating 4 SR4

Please refer to our DEFENSO brochure for more information on our advanced security range of Above Ground and Flush Fit covers

Additional specifications - abbreviations can be added to the end of the product code

*Depth of recess applies to the recessed hinged products

Cover type Loading Finish Size /Chamber Opening Opening Lift Assist Odour Seal

Locking Mechanisms

Above Ground-AG

Flush Fit-FF

Drop in Cover-TS

15 kN-1

125 kN-2

250 kN-3

400 kN-4

Solid top-S 1st dimension indicates the cover hinge side

A x B for example: 1500 x 700mm = 150 070

Hinged-A Torsion Springs-H

Compression Strut-HR

Gas Strut-U

Seal-J Padlock facility 1 Padlock-V1

Padlock facility 2 Padlocks-V2

Padlock facility 3 Padlocks etc-V3

M16 bolt (Socket head capscrew)-M16

(Padlock supplied by others)

Cover type Loading Finish Size /Chamber Opening Depth of recess

Lift Assist Odour Seal

Locking Mechanisms

Recessed Drop in Cover-TR

Recessed Hinged - RS(stainless steel strut)

Recessed Hinged - LYNX

15 kN-1

125 kN-2

250 kN-3

400 kN-4

Recessed -R

1st dimension indicates the cover hinge side

A x B for example: 600 x 600mm = 060 060

80 mm-R80

100 mm-R100

*48 mm-R48*75 mm-R75*90 mm-R90

Compression Strut -HR

Gas Strut-U

Seal-J Padlock facility 1 Padlock-V1

Padlock facility 2 Padlocks-V2

M16 bolt (Socket head capscrew)-M16

OTC bolt - VOTC

(Padlock supplied by others)

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A 300kg resistant, jail bar type grid, with a safety block at 90º, hinged on the opposite side to cover hinge would contain the following abbreviations:GS 30 J B 1 B

Secondary grid access and cut outs are also available on the safety grids, hinged or unhinged please consult us for more information.

Safety Grids

Product selection and site risk assessment are the responsibility of the project designer. The above information serves

as a guide only, our experienced technical team are available for site visits and to make recommendations on choosing

the correct access solution. Please contact us on 057 91 23100.

Our covers and frames are hot dipped galvanised to BS EN ISO 1461 - giving a coating thickness of 70 microns, which is a standard coating where corrosion resistance is required. Refer to page 17 for additional corrosion protection.

Item Load bearing Structure type Safety blocking at 90° No of parts Location of Safety Grid hinge

Safety Grid-GS 300 kg-30 Jail Bar-J Blocking-B 1 Hinged on left side - L 150 kg-15 Welded Mesh No blocking-NB 2 Hinged on right side - R (50 x 50 mm)-M05 3 Hinged on cover side - F Walk on-W 4 Hinged on opposite side to cover hinge - B

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Options: · Safety grids – see page 13 for more details·Sealed unit·Insect mesh

Locking options· M16 OTC bolt· M14 OTC bolt· M12 CHC bolt·1/4-turn OTCI

Hand operated safety blocking system

Hinged and assisted cover – for easy handling and safety for the operator, reducing the lifting to less than 25 kg.

Place of installation· Non-traffic areas only· Dry, humid, corrosive environments Material· Hot-dip galvanised mild steelOption : · Stainless steel – 304 grade standard · 316 grade optional

Smooth visible surfaceOption: tread plate – anti skid patternAnchoring bolt

holes

Locking Padlock Facility

Refer to the table for the range of clear opening sizes available in single,double,triple and multiple leaf variants

For advanced security options designed to prevent unauthorised access to key assets please refer to our DEFENSO brochure outlining our Above Ground (AG) covers and frames which are accredited by the Loss Prevention Certification Board (LPCB) in the UK, to Security Level 4

The torsion springs developed by EJ are calculated by our design engineers for each individual product:· Reducing the cover lifting effort to less than 25kg· Preventing the cover from slamming when closing· Require limited maintenance

AG range of Above Ground covers and framesDesigned to prevent the ingress of rainwaterHinged, torsion spring assisted cover

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Unobstructed clear opening for ease of access

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Clear opening: Select from table of dimensions below, 1st dimension indicates the cover hinge side

- increased thickness of zinc coating through galvanisation for enhanced durability. By increasing the thickness we can double the service life of the unit. Site specific factors which may affect the average corrosion rate (μm per annum) can be taken in account at the design stage.

- multiple leaf units

- powder coating for durability and increased resistance to corrosion. We can offer powder coating to the C5 Industrial and C5 Marine categories. Powder coated surfaces are more resistant to chipping, scratching, fading, and wearing than other finishes.

- unobstructed clear openings

Other key features for our fabricated products include:

Needs 1 padlock Needs 2 padlocks Needs 2 padlocks Needs 2 padlocks (2 master lids & 1 slave)

Dimensions in mm

B300

A 300 400400 500500 600600 700700 800800 900900 1000

1000 11001100 1200 1300 14001200 15001300 16001400 17001500 18001600 19001700 20001800190020002100220023002400250026002700280029003000310032003300

Hin

ged

Sid

e

1 cover

2 covers in-line hinged

2 covers end hinged


AG Clear opening sizes (additional dimensions available upon request)For internal openings less than 350 mm x 350 mm, the option inner leaf is always fitted

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Place of installation· Pedestrian and Parking areas · Landscaped / paved areas· Dry, humid, corrosive environmentsLoad class· 15 kN - 125 kN - 250 kN - 400 kN Material· Hot-dip galvanised mild steel Option : · Stainless steel – 304 grade standard· 316 grade optional

For advanced security options designed to prevent unauthorised access to key assets please refer to our DEFENSO brochure outlining our Flush Fit (FF) covers and frames which are accredited by the Loss Prevention Certification Board (LPCB) in the UK, to Security Levels 3 and 4.

Refer to the table for the range of clear opening sizes available in single,double,triple and multiple leaf variants

Hinged and assistedcover – for easy handling and safety for the operator,reducing the lifting toless than 25 kg.

Opening/closing assistance by torsionspring for easyhandling

Hand operated safety blocking system

Options

· Unobstructed clear opening for ease of access

· Safety grids – see page 13 for more details

· Sealed unit

Locking Padlock Facility

1/4-turn OTCI

BS Keyways spring loaded mechanism closes off keyway after removal of key

Odour Seal

FF range of Flush covers and framesDesigned for regular parking and pedestrian areasHinged, torsion spring assisted cover

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Clear opening: Select from table of dimensions below, 1st dimension indicates the cover hinge side

Dimensions in mm

B300

A 300 400

400 500

500 600

600 750

750 900

900 1000 1200 1400 1600 1800

1000 2000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

3200

3400

3600

Needs 1 padlock Needs 2 padlocks Needs 2 padlocks Needs 2 padlocks (2 master lids & 1 slave)

1 cover


2 covers end hinged


Hin

ged

Sid

e

- increased thickness of zinc coating through galvanisation for enhanced durability. By increasing the thickness we can double the service life of the unit. Site specific factors which may affect the average corrosion rate (μm per annum) can be taken in account at the design stage.

- multiple leaf units

- powder coating for durability and increased resistance to corrosion. We can offer powder coating to the C5 Industrial and C5 Marine categories. Powder coated surfaces are more resistant to chipping, scratching, fading, and wearing than other finishes.

Other key features for our fabricated products include:

FF Clear opening sizes (additional dimensions available upon request)

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Place of installation· Pavements, Parking areas,

Slow moving traffic (excluding 15kN version)

· Landscaped / paved areas· Dry, humid, corrosive environmentsLoad class· 15 kN - 125 kN - 250 kN - 400 kNMaterial· Hot-dip galvanised mild steel

Locking options Padlock Facility

M16 bolt

Non standard openings can be catered for on trenches including different angles on corners

Our fabrication facility contains the most advanced technology in the world, such as laser cutting which allows for precision parts to be designed. Customised markings are also available to indicate the type of service or utility provider.

Wide range of clear opening sizes available

BS keyways

Options· Thread plates or smooth surface· Additional anchor points· Specific keyway shapes· Safety grids see page 13 for more details

TS range of Drop-in coversSuitable for occasional access Un-hinged, un-assisted cover

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Depth of recess80 mm or 100 mm

as standardadditional options

available

Wide range of clear opening sizes available in single, double, and multiple tray variants

TR range of Recessed coversSuitable for occasional access

15kN Load Class

Place of installation· Pedestrian and Parking areas, · Slow moving traffic (except 15kN)· Landscaped / paved / public areas Load class· 15kN - 125 kN - 250 kN - 400 kN Material· Hot-dip galvanised mild steel

On large beamed multiples, one or more hinged covers with lift assist for frequent access can be integrated into the unit

Options· Locked· Sealed unit

Depth of recess80 mm or 100 mm as standard

additional options availableMesh fitted in tray to provide grip for infill material

125kN, 250kN, 400kN Load Class

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Unobstructed clear openingfor easier access

Automatic cover blocking in open position

Intuitive unblocking

Patented stainless steel spring strut for

easyclosure.

Easy and safe strutinstallation:

No gas leakage, greatly extended service life,

little or no maintenance

Invisible hinges for seamless integration into its areaof installation

Depth of recess 48mm, 75m or 90mm

Cushioning insert

Locking OTC keyOptions

Padlock facility

Place of Installation· Pedestrian and Parking areas· Landscaped / paved areas· Dry, humid, corrosive environmentsLoad class· 250 kN - 400 kN Material· Hot-dip galvanised mild steelOption· Stainless steel – 304 grade standard · 316 grade optional


The mechanical compression spring developed by EJ is calculated by our design engineers for each product to meet your safety requirements:· reduces cover lifting effort less than 25 kg· no effort to close the cover · easy and safe installation after filling· very limited maintenance required


RS range of hinged recessed coversHinged, with lift assist, maintenance free

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Place of installation· Pedestrian and Parking areas · Landscaped / paved areas · Dry, humid, corrosive environmentsLoad class· 250 kN - 400 kN · Hot- dip galvanised mild steel· Mild steel gas strut (option stainless

steel) Option· Stainless steel – 304 grade standard

Depth of recess 48 mm, 75 mm or 90 mm


Opening/closing assistance by gas strut

for easy handling

Cushioning inserts to minimise noise

Locking OTC keyOptions

Padlock facility

Option Walk on grid


LYNX range of hinged recessed coversHinged with lift assist

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Specifications

· Resistance 150 or 300 kg· Auto blocking at 90°· One man operation (lifting effort less than 25 kg)

· Lockable on request (padlock not supplied)· Removable· Delivered with a lifting chain for safety grids· Assembled on a product or wall chamber

mounting option

At EJ we incorporate safety practices into every process, product and service we provide - from design and manufacture through to distribution and end use. Our highly trained and experienced in-house product development teams will provide the optimum solutions to solve customers’ installation requirements and operational needs.

Safety and Security accessories

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2, 4, 6 part safety grids:suited for pump removal2LR (Grids hinged on adjacent sides to the Cover hinge side i.e Left and Right) 2FB (Grids hinged on parallel sides to the Cover hinge side i.e Front and Back)

used for extraction of 1 pump 4LR or 4FB Grid layout, is used for extraction of 2 pumps.6LR or 6FB Grid layout, is used for extraction of 3 pumps.

Safety railings

Various options on safety and fall protection railings are available in compliance with Health and Safety regulations.

Jail bar type grid Mesh type grid to be fixed to the chamber wall

Grids with secondary hatch or cut outAllows access to equipment without opening the grid completely.

Hinged on opposite side to cover hinge -Back

Hinged on same side to cover hinge -Front

Safety Grid

Grid

hin

ged

on R

ight

Sid

eGrid hinged on Left Side

Cover Hinge Side

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Installation InstructionsFlush Fit - FF covers and frames

1. Handle the product with slings. Check the load capacity of the slings according to the weight indicated on the product drawings.

2. Rebate: a) Prepare a rebate corresponding to the dimensions and material shown on the product drawings.

Concrete 3000 psi (20 MPa) minimum and concrete block full solid 12MPa minimum b) Clean the rebate surfaces.

3. Installation, levelling and shuttering: a) Centre the product over the clear opening of the chamber. Refer to product drawings or if necessary temporarily open the hatch and

then close it after centering. b) It is important that all anchor support points are utilised to secure the product. Anchor bolts should not be over tightened, as this can cause frame distortion/deformation. c) Create form work /shuttering if necessary. d) It is imperative that the covers are completely closed/secured while levelling the frame and during the rebate curing process.

4. Fixing: a) Prepare the concrete seal according to manufacturer’s recommendations. Concrete 3000 psi (20 MPa minimum) A quick-setting non

shrinking mortar is recommended if normal curing time for standard mortar cannot be secured (minimum 7 days). b) Pack up the mortar under frame and along the formwork. The frame must be fully in contact with the fixing material to ensure a

uniform distribution of the load and avoid distortions. c) Fill the rebate unless a layer of asphalt is specified, in which case a 20 mm depth must be left unfilled. d) Cover the filled rebate with wet canvas or tarpaulin to prevent excessive drying. Wait for complete curing of concrete.

5. Finishing a) Remove shuttering. b) Render the chamber wall with mortar if necessary. c) Open the cover and clean the entire product with water if necessary. d) Close the product.

The product is ready for use.

Flush Fit, assist lift unit

Please note these instructions are provided for general information. The contractor installing the product is responsible for carrying out local risk assessment and safely installing the product.

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Installation InstructionsAbove Ground - AG covers and frames

Ø22 mm holes provided for anchor bolts

Upstand cover, assist lift with single safety grid

Upstand cover, assist lift with 2 part safety grid

1. Handle the product with slings. Check the load capacity of the slings according to the weight

indicated on the product drawings.

2. Support: a) Prepare a chamber corresponding to the dimensions and

material shown on the product drawings. b) Clean the surfaces.

3. Installation, fixing: a) Centre the product over the clear opening of the chamber. Refer

to product drawings and open the hatch. b) Place anchor bolts into each of the Ø22 mm holes in the frame.

If the frame is in several pieces, each piece must be secured. It is important that all anchor support points are utilised to

secure the product (especially on long units with multiple hinge locations) Anchor bolts should not be over tightened, as this can cause frame distortion/deformation

4. Fixing: a) If required, pack up the mortar under the frame. The frame must be fully in contact with the fixing material to ensure a uniform distribution of load and avoid distortion.

5. Finishing: a) Clean the entire product with water if necessary. b) To ensure tightness, provide a seal between the frame and the

chamber with a suitable sealant. c) Close the product.

The product is ready for use.

Please note these instructions are provided for general information. The contractor installing the product is responsible for carrying out local risk assessment and safely installing the product.

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Rural

UrbanMari

ne

Indu

stria

l

140 μm

100 μm

65 μm

100

20 30 40 50

50

100

200

150

60 70 80 90 years

65

100 100 100 100

140 140 140

65 65 65

Coa

ting

thic

knes

s in

mic

rons

Lifetime before 1st maintenance

Galvanisation lifetime

The table above summarises the typical service life of the coating based on its thickness (65 / 100 and 140 µm) and its outdoor environment (rural/ urban/ marine and industrial).

Corrosion protection

By increasing the thickness of zinc coating through galvanisation, we can double the service life of the unit.All fabricated steel access covers by EJ are galvanised after manufacture in accordance with BS ISO 1461. This standard for corrosion protection is sufficient in most environments. However, for project sites with greater exposure to corrosion, EJ has also developed processes to effectively and sustainably increase rust prevention.By increasing the thickness of the zinc to 140 µm, the service life of the device can be doubled.

Protection by galvanisation and powder coatingIn particularly extreme indoor environments such as with industrial applications or outdoor environments such as coastal areas, where there is:· a high frequency of condensation· nearly non-existent ventilation· a highly polluted environment, with SO2 contents between 90 μg/m3 and 250 μg/m3 an additional coating such as powder coating will be required.

For the most corrosive atmospheres, take advantage of our experience and proven technologies.

Network security - protect your assetsYou can choose from a range of security options:

1. Protection against theft by using:· a captive hinge· and/or blockage by pin

2. High level of securityQuarter-turn locking:· stainless steel· with non-standard bolt head/ opening key

configurations, not commercially available

3. Optimum securityUndetectable quarter-turn locking· stainless steel· with non-standard bolt head/ opening key

configurations, not commercially available

4. Anti-terrorism security· Our DEFENSO range is LPCB certified (issue 7) by a third party the BRE laboratory in Great Britain. Available on the AG and FF ranges, used on numerous infrastructure networks throughout the world.

-

+

1 - Theft 2 - High security

Captive hingeor/and blocking pin

¼ turn locking with customised key

undetectable ¼ turn locking with customised key

1

secu

rity

4

LPCB range

2

3

4

LPS 1175: Issue 7Cert No. 1187a

3 - Optimum security 4 - Anti-terrorist security-

+

1 - Theft 2 - High security 3 - Optimum security 4 - Anti-terrorist security

Captive hingeor/and spring blocking pin

¼ turn locking with customised key

undetectable ¼ turn locking with customised key

1

secu

rity

4

LPCB range

2

3

4

LPS 1175: Issue 7Cert No. 1187a

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Global expertise. Local understanding.EJ designs, manufactures and distributes access solutions for water, sewer, drainage, telecommunications and utility networks worldwide. For over 125 years, we have fostered strong relationships around the world and we excel at serving our customers by leveraging our global and local strengths.

Castings by EJ are made from recycled materials, with ferrous scrap metals as the primary component. Every day we recycle hundreds of tonnes of post consumer material into useful products. Our solutions have a very long service life and typically require little or no maintenance. You can be assured that products that bear our name are endorsed by independent certification bodies who work to the same high standards and values as we do.

We also specialise in major civil engineering projects including airports, ports and carriageways. Our innovative range of products are specified on numerous prestigious projects throughout Ireland and the UK such as:

Dublin & Shannon Airports Port of Felixstowe Edinburgh Airport

Dublin Port Energy for Waste Projects · countrywide Belfast International Airport

M6 Birmingham Manchester Airport Edinburgh Trams

LUAS Light Rail Tram System Dublin M50 Motorway upgrade Heathrow Airport

N52 Mullingar to Tyrrellspass Corrib Natural Gas Terminal M6 Galway to Athlone Motorway

For more information on our range of innovative access solutions please call us on 057 91 23100 - to speak to one of our Sales Engineers, or visit ejco.com

PDF sales drawings Specification information Customisable project lists

Literature Videos Installation instructions

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Fabricated Steel Access Solutionsejco.com

Americas+1 800 874 4100

EMEAEurope, Middle Eastand Africa+33 344 08 28 00

Asia-Pacific+61 73216 5000

IrelandRoscrea RoadBirrCo OffalyT: 057 91 23100F: 057 91 [email protected] Fabricated Steel Access

Solutions 2015

CAVANAGH®

NORINCO® TELECOM®

SELFLEVEL®

ERMATIC®

CHILDSAFETY®

DEFENSO®

NORGUSS®

CABLECOM® NORLONG®

MAXIMO® AQUERA®

Registered marks

Fabricated Steel Access Solutions 2015

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